JP7412937B2 - 磁性材料、回転電機及び磁性材料の製造方法。 - Google Patents
磁性材料、回転電機及び磁性材料の製造方法。 Download PDFInfo
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- JP7412937B2 JP7412937B2 JP2019169520A JP2019169520A JP7412937B2 JP 7412937 B2 JP7412937 B2 JP 7412937B2 JP 2019169520 A JP2019169520 A JP 2019169520A JP 2019169520 A JP2019169520 A JP 2019169520A JP 7412937 B2 JP7412937 B2 JP 7412937B2
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/08—Cores, Yokes, or armatures made from powder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
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Description
本実施形態の複数の扁平磁性金属粒子は、扁平面と、Fe、Co及びSiを含む磁性金属相とを有し、Coの量はFeとCoの合計量に対して0.001at%以上80at%以下であり、Siの量は前記磁性金属相全体に対して0.001at%以上30at%以下であり、前記複数の扁平磁性金属粒子の平均厚さは10nm以上100μm以下であり、厚さに対する前記扁平面内の平均長さの比の平均値は5以上10000以下であり、前記扁平面内において方向による保磁力差を有する複数の扁平磁性金属粒子である。
本実施形態の複数の扁平磁性金属粒子は、扁平磁性金属粒子の表面の少なくとも一部が、厚さ0.1nm以上1μm以下で、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含む被覆層で覆われている点で、第1の実施形態と異なっている。
化学式(1)中、Rはビフェニル、トリフェニル、テトラフェニルのいずれかの構造、R’は構造内に少なくとも1つ以上の芳香環を有する構造を示す。
本実施の形態のシステム及びデバイス装置は、第3の実施の形態の磁性材料を有するものである。したがって、第1ないし第3の実施の形態と重複する内容については記載を省略する。このシステム、デバイス装置に含まれる磁性材料の部品は、例えば、各種モータや発電機などの回転電機(例えば、モータ、発電機など)、変圧器、インダクタ、トランス、チョークコイル、フィルタ等のコアや、回転電機用の磁性楔(磁性くさび)等である。図14は、第4の実施の形態のモータシステムの概念図である。モータシステムは、回転電機システムの一例である。モータシステムとは、モータの回転数や電力(出力パワー)を制御する制御系を含めたシステムのことである。モータの回転数を制御する方式としては、ブリッジサーボ回路による制御、比例電流制御、電圧比較制御、周波数同期制御、PLL(Phase Locked Loop:位相同期ループ)制御、等による制御方法がある。一例として、PLLによる制御法について図14に示してある。PLLによるモータの回転数を制御するモータシステムは、モータと、モータの回転の機械的変位量を電気信号に変換してモータの回転数を検出するロータリーエンコーダと、ある命令により与えられたモータの回転数とロータリーエンコーダにより検出されたモータの回転数を比較しそれらの回転数差を出力する位相比較器と、当該回転数差を小さくするようにモータを制御するコントローラと、を備える。一方、モータの電力を制御する方法としては、PWM(Pulse Width Modulation:パルス幅変調)制御、PAM(Pulse Amplitude Modulation:パルス電圧振幅波形)制御、ベクトル制御、パルス制御、バイポーラ駆動、ペデスタル制御、抵抗制御、等による制御方法がある。またその他の制御方法として、マイクロステップ駆動制御、多相駆動制御、インバータ制御、スイッチング制御、等の制御方法がある。一例として、インバータによる制御法について図10に示してある。インバータによるモータの電力を制御するモータシステムは、交流電源と、交流電源の出力を直流電流に変換する整流器と、当該直流電流を任意の周波数による交流に変換するインバータ回路と、当該交流により制御されるモータと、を備える。
以下に、実施例1~20を、比較例1~13と対比しながらより詳細に説明する。以下に示す実施例及び比較例によって得られる扁平磁性金属粒子について、扁平磁性金属粒子の平均厚さt、厚さに対する扁平面内の平均長さの比の平均値A、扁平磁性金属粒子の扁平面内の保磁力差の割合(%)、磁性材料の平面内の保磁力差の割合(%)、をまとめたものを表1に示す。
まず、単ロール急冷装置を用いて、Fe-Co-B-Si(Fe:Co:B:Si=552:23:19:6(at%)、Fe:Co=70:30(at%)、添加元素B+Siの合計量は、Fe+Co+B+Siの合計量に対して、25at%)のリボンを作製する。次に得られたリボンをH2雰囲気中300℃で熱処理を行う。次に、このリボンを、ミキサー装置を用いて粉砕し、H2雰囲気中で400℃で磁場中熱処理を行い、扁平磁性金属粒子を得る。得られた扁平磁性金属粒子の平均厚さtは10μm、厚さに対する扁平面内の平均長さの比の平均値Aが20である。得られた扁平磁性金属粒子は、介在相(ポリイミド樹脂)とともに混合、磁場中成型を行い(扁平粒子を配向化させる)、ホットプレス成型を実施。なお、ホットプレス成型においては、ホットプレスの金型ダイと金型パンチの間の距離(隙間)を50μmになるような構成にする。ホットプレス成型条件としては、440℃、160MPa、1時間とする。その後、磁場中熱処理を施すことによって磁性材料を得る。磁場中熱処理では、磁化容易軸方向に磁場を印加して熱処理を行う。
ホットプレス成型条件を制御することにより、得られる磁性材料の介在相量、空隙量、配向角度が表1の実施例2~8で示した値である事以外は実施例1と同じである。
扁平磁性金属粒子の平均厚さtおよび厚さに対する扁平面内の平均長さの比Aが表1の実施例9~13で示した値である事以外は実施例1と同じである。
ホットプレス成型において、ホットプレスの金型ダイと金型パンチの間の距離(隙間)を5μmになるような構成にし、成型条件を制御することにより、得られる磁性材料の介在相量、空隙量、配向角度が表1の比較例1~4で示した値である事以外は実施例1と同じである。
2b 凸部
4 磁性金属小粒子
6 扁平面
8 付着金属
9 被覆層
10 扁平磁性金属粒子
20 介在相
100 磁性材料
102 平面
200 モータ
300 モータコア
400 変圧器・トランス
500 インダクタ
Claims (12)
- 扁平面と、Fe、Co及びNiからなる群から選ばれる少なくとも1つの第1の元素を含む磁性金属相と、を有し、平均厚さは10nm以上100μm以下であり、厚さに対する前記扁平面内の平均長さの比の平均値は5以上10000以下である複数の扁平磁性金属粒子と、前記扁平磁性金属粒子間に存在し、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含む介在相と、を備える磁性材料であり、前記磁性材料において、前記介在相を体積比で4%以上17%以下含み、かつ空隙を体積比で30%以下含み、かつ、前記扁平面と前記磁性材料が有する平面との平均配向角度が10度以下である磁性材料。
- 前記磁性材料が有する平面内において、方向による保磁力差を有する請求項1記載の磁性材料。
- 前記扁平磁性金属粒子の表面の少なくとも一部が、厚さ0.1nm以上1μm以下で、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの前記第2の元素を含む被覆層で覆われている請求項1又は請求項2記載の磁性材料。
- 前記介在相が、180℃で3000時間加熱後の重量減少率が5%以下の樹脂を含む請求項1ないし請求項3いずれか一項記載の磁性材料。
- 前記磁性材料が、180℃で3000時間加熱後の重量減少率が5%以下となる請求項1ないし請求項4いずれか一項記載の磁性材料。
- 前記介在相が、熱分解温度までガラス転移点を有しない樹脂を含む請求項1ないし請求項5いずれか一項記載の磁性材料。
- 前記介在相が、ポリイミド樹脂である請求項1ないし請求項6いずれか一項記載の磁性材料。
- 請求項1ないし請求項7いずれか一項記載の磁性材料を備える回転電機。
- 請求項1ないし請求項7いずれか一項記載の磁性材料を含む磁性楔を備える回転電機。
- 請求項1ないし請求項7いずれか一項記載の磁性材料を含むコアを備える回転電機。
- 扁平面と、Fe、Co及びNiからなる群から選ばれる少なくとも1つの第1の元素を含む磁性金属相と、を有し、平均厚さは10nm以上100μm以下であり、厚さに対する前記扁平面内の平均長さの比の平均値は5以上10000以下である複数の扁平磁性金属粒子と、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含む介在相と、を混合し、
前記複数の扁平磁性金属粒子と前記介在相を、金型ダイと金型パンチの隙間が5μmより大きく100μm以下であるホットプレスを用いて、加圧及び加熱をおこない、
前記介在相を前記隙間から流出させる、
磁性材料の製造方法。 - 前記隙間は10μm以上80μm以下である、
請求項11記載の磁性材料の製造方法。
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